Self reinforced composite of thermotropic liquid crystal polymers

Claim 2

A blend of thermotropic liquid crystal polymers, said liquid crystal polymers having overlapping melt processing temperature ranges; each of said liquid crystal polymers being a wholly aromatic polyester, at least two of said liquid crystal polymers being phase separated in the solid state; said blend having a matrix phase and a fiber reinforcing phase which is formed in situ under high strain melt processing conditions; said blend containing a maximum of 98 percent by weight of any one liquid crystal polymer and conversely at least 2 percent combined weight of all other liquid crystal polymers present, based on total weight of liquid crystal polymers in said blend; said blend having greater tensile strength at break and higher impact strength than those of any constituent liquid crystal polymer in pure form.

Claim 3

A blend as claimed in claim 1 wherein a major portion of said reinforcing phase is in the form of elongated fibers having diameters not greater than about 10 microns.

Claim 4

A blend according to claim 2 wherein the preponderance of said elongated fibers have aspect ratios greater than about 10.

Claim 5

A blend according to claim 2 wherein a preponderance of said elongated fibers are essentially unidirectionally oriented.

Claim 6

A blend according to claim 1 said blend consisting essentially of said liquid crystal polymers.

Claim 7

A blend according to claim 5 in which each liquid crystal polymer is a wholly aromatic co-polyester.

Claim 8

A blend according to claim 1, said blend also containing solid reinforcing agents which are not liquid crystal polymers, each such reinforcing agent being solid at all temperatures at which said blend is melt processable.

Claim 9

A blend according to claim 1, said blend being a binary blend of two thermotropic liquid crystal polymers.

Claim 10

A blend as claimed in claim 1, said blend also having a higher tensile modulus than that of any constituent liquid crystal polymer in pure form.

Claim 11

A blend of thermotropic liquid crystal polymers as claimed in claim 1, said blend being anisotropic.

Claim 12

A process for preparing a polymer blend of two or more thermotropic liquid crystal polymers having overlapping melt processing temperature ranges, and wherein each of said liquid crystal polymers is a wholly aromatic polyester and wherein at least two liquid crystal polymers in said blend are processable in the melt phase and phase separated in the solid state, said process comprising: mixing said thermotropic liquid crystal polymers in amounts so that no one of said liquid crystal polymers constitutes more than 98 percent of the total polymer blend weight, at a temperature at which all of said polymers are melt processable, subjecting the melt of said liquid crystal polymers to high strain conditions effective to give, on cooling, a polymer blend comprising a matrix phase and a fiber reinforcing phase, extruding the resulting blend in the melt phase, cooling the blend and recovering a solid blend of said thermotropic liquid crystal polymers, said blend in the solid state being a self-reinforced polymer composite comprising a matrix phase and a fiber reinforcing phase, said fiber reinforcing phase being formed in situ under said high strain melt processing conditions.

Claim 13

A process for preparing a polymer blend of two or more thermotropic liquid crystal polymers having overlapping melt processing temperature ranges, and wherein each of said liquid crystal polymers is a wholly aromatic polyester and wherein at least two liquid crystal polymers in said blend are processable in the melt phase and phase separated in the solid state, said process comprising: mixing said thermotropic liquid crystal polymers in amounts so that no one of said liquid crystal polymers constitutes more than 98 percent of the total polymer blend weight, at a temperature at which all of said polymers are melt processable, subjecting the melt of said liquid crystal polymers to high strain conditions effective to give, on cooling, a polymer blend comprising a matrix phase and a fiber reinforcing phase, extruding the resulting blend in the melt phase, cooling the blend and recovering a solid blend of said thermotropic liquid crystal polymers, said blend in the solid state being a self-reinforced polymer composite comprising a matrix phase and a fiber reinforcing phase, said fiber reinforcing phase being formed in situ under said high strain melt processing conditions.

Claim 14

A process according to claim 11 in which said reinforcing phase is predominantly in the form of fibers having a diameter not greater than about 10 microns and an aspect ratio not less than about 10 and in which said fibers are essentially unidirectionally oriented.

Claim 15

A process according to claim 11 in which said blend is a binary blend containing two of said liquid crystal polymers.

Claim 16

A process according to claim 11 wherein said blend contains one or more solid reinforcing agents, each such reinforcing agent being solid at temperatures at which the blend is melt processable.

Claim 17

A process according to claim 11 in which each of said liquid crystal polymers is a wholly aromatic copolyester.

Claim 18

A shaped article prepared from a blend according to claim 1.